WO2013144844A1 - Procédé et appareil pour la fabrication de tissu non-tissé à partir de fibres de carbone recyclées et le tissu non-tissé ainsi formé - Google Patents
Procédé et appareil pour la fabrication de tissu non-tissé à partir de fibres de carbone recyclées et le tissu non-tissé ainsi formé Download PDFInfo
- Publication number
- WO2013144844A1 WO2013144844A1 PCT/IB2013/052405 IB2013052405W WO2013144844A1 WO 2013144844 A1 WO2013144844 A1 WO 2013144844A1 IB 2013052405 W IB2013052405 W IB 2013052405W WO 2013144844 A1 WO2013144844 A1 WO 2013144844A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fibers
- unit
- woven fabric
- lap
- mixing
- Prior art date
Links
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
- D04H1/4242—Carbon fibres
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
- D01G11/00—Disintegrating fibre-containing articles to obtain fibres for re-use
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
- D01G21/00—Combinations of machines, apparatus, or processes, e.g. for continuous processing
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/66—Disintegrating fibre-containing textile articles to obtain fibres for re-use
Definitions
- the present invention refers to an apparatus and a method for the manufacturing of a non-woven fabric, in particular a felt, from recycled carbon fibers.
- CFRPs Carbon Fiber- Reinforced Plastics
- the technical problem set and solved by the present invention is to provide a method and an apparatus for manufacturing of non-woven fabric - in particular felt - from recycled carbon fibers, overcoming the drawbacks mentioned above with reference to the known art.
- recycled carbon fibers are meant fibers recovered from other applications, in particular both pre-treated from end-of-life manufacts, and virgin fibers coming from scraps and wastes of other processings. Moreover, it will be understood that, even though the process is particularly suitable and advantageous in case of application to recycled carbon fibers, it is applicable also to commercial virgin fibers, possibly in mixture with recycled fibers.
- virgin fibers are meant precisely newly-produced, non-recycled commercial carbon fibers.
- non-woven fabric is meant an industrial product of properties similar to those of a fabric, but obtained with processes different from weaving.
- the present invention allows to obtain, starting from recovered carbon fibers, non-woven fabric suitable for the manufacturing of new finished quality products, thereby fostering recovered fibers reintroduction on the market.
- the method and the apparatus of the invention overcome the problems mentioned above with reference to the known art, related to the workability of recovered carbon fibers.
- An example of preferred industrial application of the non-woven fabric obtained with the invention is the manufacturing of reinforcement members for composite materials, in particular having a polymer matrix, today largely used in several industrial fields, among which the aeronautical, wind energy and automotive field.
- reinforcement members of non-woven fabric can be manufactured which are able to optimally adjust to complex-shape molds, giving to the composite material an adequate resistance even in zones with a very strong radius of curvature.
- complex shapes are obtained starting from elements of virgin and continuous carbon fiber, which are subjected to a lengthening process until attaining a member comprised of randomly broken filaments.
- this technology entails the limitation of a scarce predictability in fibers lengths, and of the increase in production expenses, due to the remarkable cost of yarns of virgin carbon fiber.
- the fibers are instead already in discontinuous form, and therefore relative motions between the fibers themselves are already allowed.
- the resulting non-woven fabric exhibits a "pseudo-ductility" which greatly facilitates the formability of complex-shape components, by accelerating forming operations and remarkably reducing the onset of wrinkles in the reinforcement of the composite material.
- the method of the invention allows to obtain substantially the same features of discontinuity and alignment of the known virgin fiber elements, but at a remarkably reduced cost and with a good control of fiber length.
- the semi-finished products (non-woven fabric) of recovered fibers produced with the method of the invention have a cost remarkably lower than analogous commercial products of virgin carbon fibers. Moreover, they enable to make composites with performances and mechanical properties comparable with those of the composites reinforced with virgin carbon fibers and superior to those employing fiberglass.
- the invention enables an economic exploitation of the recovered fiber and a broadening of the application field of carbon fibers to sectors where in the state of the art a use thereof would not prove economically convenient.
- the invention enables a remarkable reduction of the economical and environmental costs, also for the lack of a collection in a dump or for the lack of an incineration of CFRP products or waste or, more generally, of waste deriving from the processing of objects made of carbon fiber.
- Other advantages, features and operation steps of the present invention will be made apparent in the following detailed description of some embodiments thereof, given by way of example and not for limitative purposes.
- FIG. 1 shows a schematic flowchart illustrating a sequence of processing and/or treatment steps provided in the method of the present invention, in a preferred embodiment thereof;
- FIG. 2 shows a schematic block depiction of a preferred embodiment of apparatus carrying out the method of Figure 1 ;
- Figures 3A and 3B show each a schematic illustration of a step of adding additives of the method reported in Figure 1 , with particular reference to an ensimage step carried out by bath (Fig. 3A) and spray (Fig. 3B) technique;
- Figures 4A and 4B show each a schematic illustration of a "veil" of recovered carbon fibers, obtained by a carding step as in the method in Figure 1 , respectively made of fibers with a respectively unidirectional and random orientation;
- Figures 5A and 5B refer to two alternative modes for carrying out a lap- forming step of the method of Figure 1 ;
- FIG. 6 shows a schematic illustration of felting means used in the method in Figure 1.
- Figure 1 shows a sequence of steps according to a preferred embodiment of the method of the invention for the manufacturing of a non-woven fabric and in particular of a felt, from recycled carbon fibers.
- the method and the apparatus of the invention are also applicable to a mix of recycled fibers and virgin fibers or to virgin fibers.
- FIG. 2 shows a preferred embodiment of an apparatus specifically suitable for the carrying out of the above-mentioned method; such apparatus is generally denoted by 100.
- the method and the apparatus of the invention are suitable to the treatment of carbon fibers recovered from the recycle of composite materials or waste and scraps from the processing of carbon fibers.
- a feed system 101 e.g. a conveyor belt
- the flock or pieces of recovered carbon fiber are sent to a cutting system 102, e.g. a rotary cutter.
- a cutting system 102 e.g. a rotary cutter.
- Cut fibers are then collected, preferably always by an automatic extraction system 103 and, e.g., of conveyor belt type, and fed to the opening unit 104 for opening the flocks/pieces, so as to blend the fibrous blanket for a first time.
- the device 104 is typically a rag-grinding or tigering unit.
- additiveSj and in particular of ensimaging to the fibrous mass are added one or more products suitable to confer specific physical and/or mechanical properties to the fibers and typically water- emulsified. In particular, products suitable to foster fiber sliding and to abate the electrostatic charge thereof may be delivered.
- this step there may be envisaged the applying of a substance, referred to as "sizing", generally of epoxy type, which improves the adhesive properties of the carbon fiber.
- sizing generally of epoxy type
- the ensimage step is of remarkable significance, as it provides fibers more mechanically protected, more sliding and less prone to charge electrostatically for the subsequent treatment and processing steps.
- the ensimage step therefore allows to increase the degree of safety and the workability of the recovered fibers.
- an ensimage unit 106 has been depicted, bearing a hopper 105 for fiber inletting.
- Figures 3A and 3B show respectively a specific mode of carrying out such ensimage step.
- the depositing of an additive product on the fibers is carried out by immersion of the latter in a suitable bath 10.
- a fixed course is imposed between two conveyor belts 11 (shown as a single unit in Figure 3A) and related guide rollers, or groups of guide rollers, 1 , 2, 3 and 4.
- the course proposes to the fibers a pressing operation downstream of the bath - carried out, in the present example, between two compacting rollers 5 - and a subsequent drying operation carried out with means 6 based, e.g. on delivery of hot air or steam and/or by infrared lamps, a furnace or other system.
- the depositing of an additive product on the fibers is instead carried out by spray, in particular nebulizing by means of nozzles 12.
- the fibers are laid on a belt 13 bearing guide rollers 14 and 15, made so as to enable the product to wet the fibers and bearing the above-mentioned nebulizing rollers, preferably bilaterally.
- compacting rollers 5 and drying means 6 are provided.
- the veil and/or the lap there may be provided the applying of solid additives, such as powders or fibers, that possibly may be fixed to the fibrous matrix by a heating step (infrared lamp, steam, furnace).
- solid additives such as powders or fibers
- Such further additives can confer to the felt the ability to make preforms, and/or to the composite to be manufactured particular characteristics, like e.g., the tenacity increase.
- the mixing may be carried out with a machine or with a sequence of machines known per se, e.g.: - a bale opening machine with a micro-weighing system, which enables the feeding of the individual components guaranteeing perfect control of the amounts fed (a machine suitable to said purpose is the commercial model denominated Bale opener mod. AB, produced by Cormatex),
- the percentage of auxiliary fibers added to the mass of carbon fibers being input can be variable and adjustable, depending on the processing specifications and in particular on the non-woven fabric that is to be obtained as output.
- the method and the apparatus described herein provide the manufacturing of felts with 95% of carbon fibers.
- the method and the apparatus of the invention enable the manufacturing of felts with percentages of carbon fibers variable over a very wide range.
- Auxiliary fibers may be of organic nature, as well as of inorganic nature.
- suitable auxiliary fibers thermoplastic fibers of polyester, Polyetheretherketone (PEEK), polytetrafluoroethylene (PTFE), polyethersulfones (PES), polyamides (PA), polypropylene (PP), polyethylene (PE), polystyrene (PS), polyvinyl alcohol (PVA) type; natural fibers of cotton, hemp, flax type; inorganic fibers of metallic, glass and aramid type.
- the auxiliary fibers may have a supporting function for the subsequent steps, in particular a lap-forming step which will be introduced below in the description, and/or also confer specific functional properties to the non-woven fabric that is output and to the finished product (composite material reinforced with carbon fibers) manufactured therewith.
- the mixing step may be carried out concomitantly to a step of adding additives, and in particular of ensimaging, additional or alternative to that described above.
- Said step of adding additives may be carried out according to modes analogous to those already described in connection with Figures 3A and 3B.
- the blended fibrous mass is then subjected to a fiber arranging, or orienting operation, in a suitable unit 108 at the output of which a so-called "veil" is obtained.
- a fiber orienting step is a carding step, carried out in a suitable carding machine.
- Figure 4A shows, by way of example, a veil bearing fibers with a prevailing and predefined unidirectional orientation.
- Figure 4B shows instead, always by way of example, a veil bearing fibers with a random orientation.
- laps can be manufactured with veils having fibers of predefined or random orientation, and with fibers oriented unidirectionally, two- directionally or three-dimensionally.
- the specific orientation of the fibers in the lap may be obtained by imparting suitable working motions to a lap-forming manufacturing machine.
- an overlapping of veils may be provided in a direction parallel or transversal to the advancement of the lap on such manufacturing machine.
- Two examples of lap manufacturing in a manufacturing machine are shown in Figures 5A and 5B.
- V denotes the veil
- arrows 20a, 20b the overlap direction of the veils or of the veil portions
- the arrow 21 the direction of advancement of a conveyor belt 22 or equivalent means on which the veil or veils constituting the lap are laid.
- the resulting lap has fibers in a chiefly longitudinal direction when the starting veil has unidirectional fibers and the overlap direction 20a corresponds to the direction of orientation of the veil fibers. Therefore, in the case of Figure 5A the veils are parallely overlapped the one on the other until forming the desired lap thickness.
- the veil is laid along direction 20b, transversally to the feed motion of the conveyor belt 22, enabling to obtain infinite lengths of lap.
- the veil is therefore laid transversally to the feed motion of the lap, enabling to obtain infinite lengths of lap.
- a step of adding additives in particular of ensimaging, can be introduced additional or alternative to those described above.
- the step of orienting fibers and that of lap-forming just described may also be carried out concomitantly the one to the other. This is possible, e.g., when using the above-mentioned aerodynamic carding.
- a heating of the lap by thermal treatment carried out e.g. by irradiation lamp, hot-air furnace, steam, etc., and
- the temperatures that can be utilized for the forming can range from 80 to 200 °C, according to the material utilized for veil sizing.
- Figure 6 shows a diagram exemplary of the mode of carrying out such forming step, referring in particular to a felting.
- the lap denoted by F
- the lap is thermoformed by feeding to a heating device 30 followed by a rolling mill 31 , at the output of which precisely a non-woven fabric tnt of desired thickness is obtained.
- the lap may be cohesioned by chemical bonds instead of by thermoforming.
- the conveyor belt of Figure 3A may be replaced by a belt for guiding only.
- the system may be completed by a device for rolling up the non- woven fabric on a spindle.
- the devices and the units of the above-described apparatus 100 may be equipped with means, per se known, suitable to prevent the carbon fiber, particularly conductive electrically, from damaging electrical parts, control systems and/or safety devices.
- Hoods, shields, protections, wirings and the like are the most common known precautions for performing this task.
- the various sections of the apparatus 100 may be under negative pressure, in order to prevent the dispersion of the fibers themselves in the work environment. This contrivance eliminates the problems linked to the healthiness of the environments and to the integrity of the machines (short circuits).
- the non-woven fabric obtained with the method and the apparatus described above may have mechanical and physical properties variable depending on the applicative needs, e.g. in terms of height, thickness, grammage, percentage and type of auxiliary fiber, percentage and type of additive/s and degree of fiber parallelism.
- the non-woven fabric provided by the above-described apparatus and method can be managed as known non-woven fabrics and therefore can undergo subsequent processing processes, e.g. of preforming, pre-impregnation, impregnation, etc.
- the non-woven fabric obtained allows the design and manufacturing of composite materials and products of carbon fiber having selected high mechanical properties - in particular, strength, mechanical rigidity and tenacity - even with respect to the different directions, concomitantly optimizing the use of the material. Therefore, a composite material manufactured with the non-woven fabric of the invention proves to have mechanical features, mentioned above by weight unit, comparable to those obtained by the most performing among the materials manufactured with the known art.
- the non-woven fabric obtained may be utilized as is for specific applications, e.g. electro-magnetic shielding, or temperature filtering systems, or be pre-impregnated for CFRP manufacturing.
- a carbon fiber-reinforced composite material starting from the non- woven fabric obtained with the above-described apparatus 100 and method can be manufactured by several known techniques, among which, purely by way of example, the following are mentioned: “manual rolling”, “vacuum bag molding”, “hot molding”, which therefore will not specifically be dwelt upon.
- the present invention has been hereto described with reference to preferred embodiments thereof. It is understood that other embodiments might exist, all falling within the concept of the same invention, as defined by the protective scope of the claims hereinafter.
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Inorganic Fibers (AREA)
- Treatment Of Fiber Materials (AREA)
- Nonwoven Fabrics (AREA)
Abstract
un procédé et un appareil (100) de fabrication d'un produit non-tissé à partir de fibres de carbone recyclées, étant sous la forme de flocs, pièce, etc, et le tissu non-tissé, pour lequel le procédé comprend les étapes consistant à :- couper des fibres de façon discontinue, de manière à obtenir une taille homogène de fibres de longueur sélectionnée ;-mélanger les fibres avec des fibres auxiliaires, de manière concomitante et ultérieure à l'étape de coupe ;-o orienter et rendre cohésives les fibres mélangées dans l'étape précédente pour obtenir une nappe de fibres ; et former la nappe obtenue dans l' étape précédente pour obtenir le tissu non - tissé.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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ITRM2012A000118 | 2012-03-26 | ||
IT000118A ITRM20120118A1 (it) | 2012-03-26 | 2012-03-26 | Metodo per la realizzazione di feltri da fibre di carbonio di riciclo. |
Publications (1)
Publication Number | Publication Date |
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WO2013144844A1 true WO2013144844A1 (fr) | 2013-10-03 |
Family
ID=46584146
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/IB2013/052405 WO2013144844A1 (fr) | 2012-03-26 | 2013-03-26 | Procédé et appareil pour la fabrication de tissu non-tissé à partir de fibres de carbone recyclées et le tissu non-tissé ainsi formé |
Country Status (2)
Country | Link |
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IT (1) | ITRM20120118A1 (fr) |
WO (1) | WO2013144844A1 (fr) |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20130209724A1 (en) * | 2010-11-03 | 2013-08-15 | Sgl Carbon Se | Pile layer with carbon-fiber encompassing bundles |
DE102014013532A1 (de) | 2014-09-12 | 2016-03-17 | Airbus Operations Gmbh | Honigwabenstruktur aus einem vlies aus rezyklierten kohlenstofffasern |
WO2017191024A1 (fr) * | 2016-05-04 | 2017-11-09 | Tenowo GmbH | Produit plat non-tissé textile pouvant être calandré |
DE102016113721A1 (de) * | 2016-07-26 | 2018-02-01 | Autefa Solutions Germany Gmbh | Faserflor-basiertes bahnförmiges Textil mit unidirektional erhöhter Festigkeit |
US10160620B2 (en) | 2015-01-09 | 2018-12-25 | Otis Elevator Company | Tension member for elevator system |
CN109206842A (zh) * | 2018-08-20 | 2019-01-15 | 南昌大学 | 一种连续碳纤维聚醚醚酮复合材料的制备方法 |
CN110341290A (zh) * | 2019-07-16 | 2019-10-18 | 安国市前进无纺布有限公司 | 短纤复合式加筋或加网无纺布生产设备及工艺 |
IT201900001681A1 (it) * | 2019-02-06 | 2020-08-06 | Vincenzo Tagliaferri | Nuovo materiale composito per l’alleggerimento di varie strutture. |
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Cited By (13)
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US20130209724A1 (en) * | 2010-11-03 | 2013-08-15 | Sgl Carbon Se | Pile layer with carbon-fiber encompassing bundles |
US20130287991A1 (en) * | 2010-11-03 | 2013-10-31 | Sgl Carbon Se | Pile layer with curved bundles |
US9551098B2 (en) * | 2010-11-03 | 2017-01-24 | Sgl Automotive Carbon Fibers Gmbh & Co. Kg | Nonwoven batt with curved carbon fiber bundles |
DE102014013532A1 (de) | 2014-09-12 | 2016-03-17 | Airbus Operations Gmbh | Honigwabenstruktur aus einem vlies aus rezyklierten kohlenstofffasern |
US10167583B2 (en) | 2014-09-12 | 2019-01-01 | Airbus Operations Gmbh | Honeycomb structure made of a non-woven made of recycled carbon fibers |
US10160620B2 (en) | 2015-01-09 | 2018-12-25 | Otis Elevator Company | Tension member for elevator system |
WO2017191024A1 (fr) * | 2016-05-04 | 2017-11-09 | Tenowo GmbH | Produit plat non-tissé textile pouvant être calandré |
DE102016113721A1 (de) * | 2016-07-26 | 2018-02-01 | Autefa Solutions Germany Gmbh | Faserflor-basiertes bahnförmiges Textil mit unidirektional erhöhter Festigkeit |
CN109206842A (zh) * | 2018-08-20 | 2019-01-15 | 南昌大学 | 一种连续碳纤维聚醚醚酮复合材料的制备方法 |
CN109206842B (zh) * | 2018-08-20 | 2021-05-07 | 南昌大学 | 一种连续碳纤维聚醚醚酮复合材料的制备方法 |
IT201900001681A1 (it) * | 2019-02-06 | 2020-08-06 | Vincenzo Tagliaferri | Nuovo materiale composito per l’alleggerimento di varie strutture. |
WO2020161220A1 (fr) * | 2019-02-06 | 2020-08-13 | Frattelli Mazzocchia S.P.A. | Matériau composite pour alléger diverses structures |
CN110341290A (zh) * | 2019-07-16 | 2019-10-18 | 安国市前进无纺布有限公司 | 短纤复合式加筋或加网无纺布生产设备及工艺 |
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